Systems and methods for installing cladding panels

ABSTRACT

A hanging system for securing cladding panel on a building structure, the cladding panel having a mounting channel extending at least partly across a surface thereof. An embedded anchor block has a core and two engaging portions outwardly projecting from the core, the two engaging portions operable to lock the anchor block in the mounting channel of the cladding panel in an interlocking fit when the embedded anchor block is received within the mounting channel, and the embedded anchor block having an outer surface that is configured to be flush or near flush with the surface of the cladding panel when the embedded anchor block is received within the mounting channel. A hanging clip removably connects or fastens to the anchor block, the hanging clip having an engagement surface to engage the outer surface of the anchor block. The cladding panel is secured to a building structure by fastening the anchor block to the hanging clip which is securable to a support.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.14/955,720 filed Dec. 1, 2015, which claims the benefit of U.S.Provisional Application No. 62/118,751 filed Feb. 20, 2015 which isherein incorporated by reference in its entirety.

FIELD

The embodiments disclosed herein generally relate to the field ofcladding, façade, and curtain walls. More specifically, the embodimentsrelate to anchoring cladding panels onto a building structure.

BACKGROUND

Stone, due to its rich colors, different varieties, elegant appearance,durability and other characteristics, is widely used as outdoor andindoor decoration material for all types of buildings. Syntheticmaterials are manufactured for all kinds of applications for not onlytheir beautiful appearance and durability, but also their green andenvironmental-friendly characteristics. They are now very popularmaterials in the construction industry.

Due to the physical properties of stone, connecting or coupling thecladding panels with the main body of the building adds a certain degreeof difficulty. In the traditional “wet adhesive” attaching method, suchas using mortar or adhesive, the cladding panels in direct contact withthe concrete block of building. It may seriously affect the decorativefunction and create many problems, even some safety issues. As comparingto the “wet adhesive” attaching method, some currently used fixingmethods (dry-hanging methods) may overcome some of the above mentionedshortcomings by installing the cladding panels indirectly onto concretesurface of the building, such as through dowel pin anchor, Kerf anchor,undercut fastener (or back bolting) connection and so on. But thesehanging processes also have their own deficiencies. For example, theseprocesses need holes to be manually drilled or slots to be manually cutby workers on the construction site. Adhesive for fixing anchor oncladding panel is also applied on site. These processes require longerconstruction time, more operations and highly skilled workers, such asexperienced masons. At the same time, there may be also negative impacton construction quality by climate or environmental factors, such as incold winter time. Furthermore, certain facilities and equipment may berequired to create the features on cladding panel, and a certain extentof environment pollution is inevitable. Among these commonly usedinstallation methods, undercut fastener (or back bolting) connection maybe an improvement over dowel pin and kerf anchors. For example, the mainprocess is completed within the fabrication shop instead of on site, butits structure designed to take external forces carries a risk increating relatively high stress in the cladding material. As aconsequence, the method of undercut fastener connection still has somedrawbacks, such as limitations imposed on the thickness of claddingmaterial and the overall size of panel.

Accordingly there exists a need for improved methods and systems forcladding.

SUMMARY

In accordance with one aspect, there is provided a cladding panelassembly having a cladding panel comprising a mounting channel extendingat least partly across a surface thereof. An embedded anchor block has acore and two engaging portions outwardly projecting from the core, thetwo engaging portions operable to lock the embedded anchor block in themounting channel of the cladding panel in an interlocking fit when theembedded anchor block is received within the mounting channel, and theembedded anchor block having an outer surface that is configured to beflush or near flush with the surface of the cladding panel when theembedded anchor block is received within the mounting channel.

In some embodiments, the embedded anchor block has a dovetail shape.

In some embodiments, the mounting channel has a cross sectioncomplementary to a cross section of a shape of the embedded anchorblock.

In some embodiments, the assembly has a hanging clip configured toremovably connect or fasten to the embedded anchor block, the hangingclip having an engagement surface to engage the outer surface of theembedded anchor block, wherein the cladding panel is operable to besecured to a building structure by fastening the embedded anchor blockto the hanging clip which is securable to a support.

In some embodiments, embedded anchor block has at least one boreextending inward from the outer surface, and the hanging clip having atleast one corresponding bore to removably connect or fasten the hangingclip to the embedded anchor block.

In some embodiments, the hanging clip has a body and a flange projectingoutwardly from the body, the body having the at least one correspondingslot or bore to the at least one bore of the embedded anchor block forremovably connecting or fastening the embedded anchor block.

In some embodiments, adhesive material fills a gap between the embeddedanchor block and an inner surface of the mounting channel when theembedded anchor block is received within the mounting channel. Theadhesive material may be epoxy.

In some embodiments, the outer surface of the embedded anchor block hasgrooves thereon for preventing slippage when removably connected orfastened with the engagement surface of the hanging clip.

In some embodiments, the engagement surface of the hanging clip hasgrooves thereon for preventing slippage when removably connected orfastened with the embedded anchor block.

In some embodiments, the cladding panel has a reinforcing layer on thesurface. The reinforcing layer may be in a form of at least one ofcloth, mesh and grating.

In some embodiments, the hanging clip is configured for an adjustableconnection to the embedded anchor block to provide a plurality ofassembly configurations.

In some embodiments, the at least one bore on the body of the hangingclip is configured to provide vertical adjustment during claddinginstallation.

In another aspect, there is provided a kit for hanging a cladding panelonto a building structure, the cladding panel comprising a mountingchannel extending at least partly across a surface thereof. The kit hasan anchor block having a core and two engaging portions outwardlyprojecting from the core, the two engaging portions operable to lock theanchor block in the mounting channel of the cladding panel in aninterlocking fit when the embedded anchor block is received within themounting channel, and the embedded anchor block having an outer surfacethat is configured to be flush or near flush with the surface of thecladding panel when the embedded anchor block is received within themounting channel. The kit has a hanging clip configured to removablyconnect or fasten to the anchor block, the hanging clip having anengagement surface to engage the outer surface of the anchor block,wherein the cladding panel is operable to be secured to a buildingstructure by fastening the anchor block to the hanging clip which issecurable to a support.

In some embodiments, the anchor block has at least one bore extendinginward from the outer surface and wherein the hanging clip has at leastone corresponding bore to removably connect or fasten the hanging clipto the anchor block.

In some embodiments, the hanging clip has a body and a flange projectingoutwardly from the body, wherein the body having the at least onecorresponding slot or bore to the at least one bore of the anchor blockfor removably connecting or fastening the anchor block.

In some embodiments, the outer surface of the anchor block has groovesthereon for preventing slippage when removably connected or fastenedwith the engagement surface of the hanging clip.

In some embodiments, the engagement surface of the hanging clip hasgrooves thereon for preventing slippage when removably connected orfastened with the anchor block.

In some embodiments, the hanging clip is configured for an adjustableconnection to the anchor block to provide a plurality of assemblyconfigurations. For example, the cladding may be at different positionson the building and the hanging clip can change attachmentconfigurations with embedded anchor block depending on cladding itsecures. For example, bottom cladding may be supported by a differenthanging clip attachment configuration than upper cladding. As anotherexample, a different attachment configuration for the hanging clip maybe used to secure multiple panels together and may vary depending on thenumber and position of the cladding panels.

In some embodiments, at least one bore on the body of the hanging clipis configured to provide vertical adjustment during claddinginstallation.

In another aspect, there is provided an anchor block having a core andtwo engaging portions outwardly projecting from the core, the twoengaging portions operable to lock the anchor block in a mountingchannel of a cladding panel in an interlocking fit when the anchor blockis received or embedded within the mounting channel, and the anchorblock having an outer surface that is configured to be flush or nearflush with an surface of the cladding panel when the anchor block isreceived within the mounting channel, such that the cladding panel isoperable to be secured to a building structure by engaging the anchorblock.

In some embodiments, the anchor block has a dovetail shape.

In some embodiments, the anchor block has at least one bore extendinginward from the outer surface, the bore being adapted to receive afastener.

In some embodiments, adhesive material fills a gap between the anchorblock and an inner surface of the mounting channel when the anchor blockis received within the mounting channel. In some embodiments, theadhesive material is epoxy.

In some embodiments, the outer surface of the anchor block comprisesgrooves thereon for preventing slippage.

In another aspect, there is provided a method for installing a claddingpanel onto a building structure, the cladding panel having a mountingchannel extended across at least a part of a surface of the claddingpanel, the anchor block having at least one bore extending inwardly froman outer surface thereof. The method may involve embedding the anchorblock into the mounting channel of the cladding panel in an interlockingfit, such that an outer surface of the anchor block is flush or nearflush with the surface of the cladding panel when the anchor block isreceived within the mounting channel; removably securing a hanging clipto the embedded anchor block by inserting a fastener through acorresponding bore extending through a body of the hanging clip and theat least one bore of the anchor block; and securing the cladding panelonto the building structure by connecting or fastening the hanging clipto a support.

In some embodiments, the method may involve sliding the anchor blockinto the mounting channel of the cladding panel.

In some embodiments, the method may involve filling a gap between themounting channel and the embedded anchor block with adhesive material.

In some embodiments, the method may involve embedding the anchor blockin position within the mounting channel using elastic materials.

In some embodiments, the anchor block has a core and two engagingportions outwardly projecting from the core, the two engaging portionsoperable to lock the anchor block in the mounting channel of thecladding panel in the interlocking fit when the embedded anchor block isreceived within the mounting channel.

In some embodiments, the mounting channel has a cross sectioncomplementary to a cross section of a shape of the embedded anchorblock.

In some embodiments, the hanging clip comprises an engagement surface toengage the outer surface of the embedded anchor block.

In some embodiments, the hanging clip is removably connected or fastenedwith the anchor block by a threaded bolt or an expansion bolt.

In some embodiments, the method may involve adjusting a position of thehanging clip through the at least one corresponding bore to providevertical adjustment of the cladding panel relative to the support.

In some embodiments, the support is removably coupled to the buildingstructure and comprises at least one of an L bracket and a T bracket.

In some embodiments, the method may involve adjusting a position of thesupport to provide at least a horizontal adjustment of the claddingpanel relative to the support.

In some embodiments, the anchor block comprises at least one of metaland reinforced plastics.

In some embodiments, the anchor block is linear or arc-shaped.

Other example embodiments are described herein.

BRIEF DESCRIPTION OF FIGURES

In the figures, various aspects and embodiments are shown, and describedin connection therewith.

FIG. 1 is a cross-sectional view of an example system for hanging oranchoring cladding;

FIG. 2A is a perspective view showing an example system of cladding witha plurality of example cladding assemblies;

FIG. 2B shows perspective views of different components of a claddingassembly;

FIG. 3 shows a perspective view of another example system of claddingwith a plurality of example cladding assemblies;

FIG. 4A shows perspective views of different configurations of examplecladding assemblies for top panels;

FIG. 4B shows perspective views of additional different configurationsof example cladding assemblies for middle panels;

FIG. 4C shows perspective views of further different configurations ofexample cladding assemblies for bottom panels;

FIG. 5 is an exploded view of an example anchor block and an examplehanging clip system with a cladding panel;

FIG. 6 is a perspective view of an example hanging clip;

FIG. 7 is a perspective view of an example anchor block;

FIG. 8A shows a cross-sectional view of an example anchor block withdovetail portions;

FIG. 8B shows a cross-sectional view of an example anchor block withsquare portions;

FIG. 8C shows a cross-sectional view of an example anchor block withround portions;

FIG. 9 shows a side view of an example anchor block embedded within acladding panel and an example hanging clip removably fastened to theanchor block;

FIG. 10A demonstrates stress analysis on cladding panel;

FIG. 10B demonstrates stress analysis on an anchor block and a hangingclip providing a hanging assembly;

FIG. 11 shows deflection analysis for a cladding supporting structure;and

FIG. 12 shows an example installation sequence of the cladding assemblysystem.

DETAILED DESCRIPTION

The discussion herein provides many example embodiments of the inventivesubject matter. Although each embodiment represents a single combinationof inventive elements, all possible combinations of the disclosedelements are considered to include inventive subject matter. Thus if oneembodiment comprises elements A, B, and C, and a second embodimentcomprises elements B and D, then the inventive subject matter is alsoconsidered to include other remaining combinations of A, B, C, or D,even if not explicitly disclosed.

As used herein, and unless the context dictates otherwise, the term“coupled to” is intended to include both direct coupling (in which twoelements that are coupled to each other contact each other) and indirectcoupling (in which at least one additional element is located betweenthe two elements). Therefore, the terms “coupled to” and “coupled with”are used synonymously.

Described herein are systems and methods for hanging or anchoringcladding panels onto a building structure using cladding assemblies. Anexample cladding assembly may have an anchor block and a hanging clip.The anchor block may be referred to as an embedded anchor block with anouter surface that is configured to be flush or near flush with thesurface of the cladding panel when the embedded anchor block is receivedwithin the mounting channel. Accordingly, the anchor block is “embedded”within the cladding panels. The cladding assembly may include anadhesive when an embedded anchor block is received within a claddingpanel. The embedded anchor block may have a dovetail shape thatcomplements a corresponding dovetail shape slot or mounting channel inthe cladding panel. The embedded anchor block may be removably connectedor fastened to the hanging clip. This may provide flexibility asdifferent types of hanging clips may be used. The cladding assembly mayenable replacement or removal of individual cladding panels or piecesduring installation or repair. In addition, the embedded anchor blockand hanging clip may facilitate certain amount of adjustability and theinterlocking nature between the anchor block and the cladding panel, aswell as between the hanging clip and the support structure, help avoidthe need to put a bolt/fastener into the cladding panel itself duringinstallation. The anchor block may be referred to herein as an embeddedanchor block as it is configured to be received within a channel of thecladding panel.

FIG. 1 is a cross-sectional view of an example system for hanging oranchoring cladding. As shown, a cladding assembly system 600 mayfacilitating the hanging of one or more cladding panels 300 onto abuilding structure 500. The system 600 may include an embedded anchorblock 100 within a cladding panel 300 and a hanging clip 200 removablyconnected or fastened to the anchor block 100 by a fastener 260.

The embedded anchor block 100 may be received within a mounting channel320 extending at least partly across a surface 310 of cladding panel300. When received within the mounting channel 320, an adhesive material620 may be used to fill a gap between the anchor block 100 and interiorsurface of mounting channel 320 of cladding panel 300. An exampleadhesive may be epoxy. In some embodiments, adhesive 620 may act as alock and buffer for the cladding and the hanging assembly material. Theadhesive 620 may provide a degree of elasticity between embedded anchorblock 100 and cladding panel 300. This may be beneficial as materials ofpanel and embedded anchor may expand or contract at different extentsdue to temperature variation. For example, stone may expand in summer.

Referring now to FIG. 9, which shows a side view of an example embeddedanchor block within a cladding panel and an example hanging clipremovably fastened or connected to the anchor block, epoxy adhesive canalso help eliminate or reduce direct contact between metal and cladding,and also take the sheer load.

Fastener 260 may be any suitable fastening means, for example, it may bea threaded bolt or expansion bolt.

Once a hanging clip 200 has been fastened to anchor block 100, a supportstructure or frame (or simply “support”) 400 may be further removablyconnected or fastened to the hanging clip 200 and the cladding panel300, for example in interlocking fit, to hang the cladding panel ontothe building structure 500. Support 400 may include a number ofconfigurations suitable to help secure the cladding panel onto thebuilding structure with a hanging clip and an anchor block. For example,in FIG. 1, support 400 may include one or more of a T bracket or angle420 and a L bracket 410, as shown. T bracket 420 may be removablyconnected or fastened to L bracket 410 by a fastener 450, which maycomprise, for example, a bolt. The support 400 may be further removablyconnected or fastened to building structure 500 by a fastener 430, suchas a bolt.

In some embodiment, as shown, an outer surface 130 of the embeddedanchor block 100 is flush or near flush with a back surface 310 ofcladding panel 300 when anchor block 100 is received within the claddingpanel 300. This also allows an embedded depth of anchor block 100 to beconsistent regardless of the thickness of cladding material or panel300. That is, the anchor block is embedded within the cladding panel. Inaddition, a plurality of cladding panels, each with an anchor block 100embedded, may be stacked with minimal wasted space between the panels asthe anchor surface may be flush or near flush with the cladding panel300, which improve product packing efficiency, and do not adverselyaffect the transportation. Shipping cost may be thereby saved.

In some embodiments, after fastening of hanging clip 200 onto anchorblock 100, the cladding panels is installed on a keel system (orsupporting frame) by a hanging method. If there is no keel system (orsupporting frame) is installed, the cladding panel with hanging clipscan be directly installed on supporting brackets 410, 420 which may beremovably connected on building concrete block or steel structure 500.The location and number of connection points may be laid out accordingto pre-determined design and installation requirements.

In some embodiments, as assembled, a distance between the backside ofthe cladding panel 300 and the surface of the building structure 500 maybe any were from 1 to 4 inches, as an illustrative example.

As described herein, the method of hanging a cladding panel 300 onto abuilding structure 500 is not restricted by surface conditions ofcladding panel 300. The cladding surface can be in the format of flatplane, cylinder or other irregular shapes.

In some embodiments, support 400, hanging clip 200 and anchor block 100as embedded within cladding panel 300 may together be referred to as acladding assembly 600.

Referring now to FIG. 2A, a perspective view showing an example systemof cladding with a plurality of example cladding assemblies is provided.A plurality of cladding panels 300 may be removably connected togetherby a plurality of cladding assemblies 600. For example, an anchor blockand hanging clip assembly 600 that overlaps two or more panels may helpwith easy installation. For example, as shown in the blow-out view,cladding assembly 600 may comprise a plurality (e.g. four) anchor blocks100 (not shown), each embedded within a corresponding cladding panel300. Each anchor block 100 may be removably fastened to a correspondinghanging clip 200 a, 200 b, 200 c (fourth hanging clip not visible). Eachhanging clip 200 a, 200 b, 200 c may be fastened to the correspondinganchor block 100 by way of one or more bores 220. A T bracket 420 may beremovably fastened to the plurality of the hanging clips by way ofinterlocking fit. In one embodiment, the T bracket may be in aninterlocking fit with a flange portion of each of the hanging clips 200a, 200 b, 200 c.

Each T bracket 420 may have one or more bores or slots 425 a, 425 b,each for receiving a fastener 450 a, 450 b. The fasteners 450 a, 450 bmay removably secure a L bracket 410 onto the T bracket 420. L bracket410 may comprise one or more bores for receiving one or more fasteners430 a, 430 b. Fasteners 430 a, 430 b may further removably secure thecladding assembly 600, thus the entire cladding structure, onto abuilding structure 500.

Referring now to FIG. 2B, a cladding assembly 600 may be easily adjustedin three directions, namely X, Y and Z, as shown. In X direction,flexibility and adjustability may be provided by adjustable placement offastener 450 through an elongated slot or bore 425 on bracket 420. In Ydirection, sliding one or more brackets 410, 420 in either direction mayprovide adjustability within a certain range of the cladding assembly600. In Z direction, the adjustment of vertical location of claddingpanel 300 can be quickly achieved by using shims with slot or bore 220and fastener 260. This capability in free adjustment in three dimensionsmay improve accuracy of location of panel installation duringconstruction process.

Referring now to FIG. 3, which shows a perspective view of anotherexample system of cladding with a plurality of example claddingassemblies: configuration details A, B and C show various configurationsof cladding assemblies 600 installed for top panels; configurationdetails D, E and F show various configurations of cladding assemblies600 installed for middle panels; and configuration details G, H and Jshow various configurations of cladding assemblies 600 installed forbottom panels. As can be seen from FIGS. 4A to 4C, for each of details Ato J, the cladding assembly on the left panel(s) may have identicalcomponents and configuration as cladding assembly on the right panel(s).

As described herein, the various configurations of cladding assembliesallow constructions workers to install individual cladding panels anorder other than bottom-panels-first That is, as each cladding panel canhold its own weight by being connected to a building structure via thecladding assembly, bottom panels do not have to be installed first.Traditionally, construction workers would have to install the bottompanels first as the bottom panels have to act as a support to a gravitywall and hold the weight of the upper panels.

FIG. 4A shows perspective views of different configurations of examplecladding assemblies for top panels. Referring now to detail A, whichshows two cladding assemblies 600 a, 600 b each mounted on respectivetop cladding panel 300 a, 300 b, as these two panels 300 a, 300 b areassembled to form a corner of less than or equal to 90 degrees. Hiddenfrom view are anchor blocks 100 locked within mounting channels 320 a,320 b. As can be seen, the cladding assembly 600 a on the left hasidentical components and configuration as cladding assembly 600 b on theright. Referring now to cladding assembly 600 b installed on the rightcladding panel 300 b in detail A, only one anchor block 100 and onecorresponding hanging clip 200 are required. Two bores 220 a, 220 b maybe drilled in the hanging clip 200 b for receiving fasteners 260 inorder to removably fasten the hanging clip 200 b to the correspondinganchor block 100 thus the panel 300 b. In addition, support 400 maycomprise two L brackets 410 a, 410 b. One of the L brackets 410 b mayhave two bores for receiving corresponding fasteners 430 a, 430 b whenmounted to a building structure (not shown).

Detail C in FIG. 4A shows identical assemblies 600 a, 600 b as those indetail A, except that in detail C, these two cladding panels 300 a, 300b are assembled to form a corner greater than 90 degrees (e.g. 270degrees).

Detail B in FIG. 4A shows a cladding assembly 600 for securing two toppanels in the middle, which form more or less a flat or relatively flatsurface. Similar to detail A, each cladding panel has an anchor block100 mounted within a mounting channel 320 and removably fastened to acorresponding hanging clip 200 a, 200 b. A single piece L bracket 410 bmay be used to interlock both hanging clips 200 a, 200 b, and anothersingle piece L bracket 410 a may be removably fastened onto bracket 410b. L bracket 410 a may have two slots or bores for receivingcorresponding fasteners 430 a, 430 b when mounted to a buildingstructure (not shown).

FIG. 4B shows perspective views of additional different configurationsof example cladding assemblies for middle panels 300 a, 300 b, 300 c,300 d. Referring now to detail D, which shows two cladding assemblies600 a, 600 b each mounted on respective middle cladding panels as thesefour panels 300 a, 300 b, 300 c, 300 d are assembled to form a corner ofless than or equal to 90 degrees. As can be seen, the cladding assembly600 a on the left has identical components and configuration as claddingassembly 600 b on the right. Referring now to cladding assembly 600 binstalled on the right cladding panels 300 b, 300 d in detail D, hiddenfrom view are a plurality (e.g. two) of anchor blocks 100, each lockedwithin a respective mounting channel 320 a, 320 b, where each mountingchannel 320 a, 320 b extends across at least partly across a surface 310of a respective panel 300 b, 300 d. For each anchor block 100, acorresponding hanging clip 200 a, 200 b is fastened thereto. That is,each panel 300 a, 300 b, 300 c, 300 d may have its ownanchor-block-and-hanging-clip system installed thereon. Two bores 220 a,220 b may be drilled in each of the hanging clips 200 a, 200 b forreceiving fasteners 260 in order to removably fasten the hanging clips200 a, 200 b to the corresponding anchor block 100 thus the claddingpanel 300 b, 300 d. For assembly 600 b in detail D, hanging clip 200 aand hanging clip 200 b may share one support structure 400. Support 400may comprise a L bracket 410 and a T bracket 420. L bracket 410 may havetwo or more bores for receiving corresponding fasteners 430 a, 430 bwhen mounted to a building structure (not shown).

Detail F in FIG. 4B shows identical assemblies 600 a, 600 b as those indetail D, except that in detail F, these four cladding panels 300 a, 300b, 300 c, 300 d are assembled to form a corner greater than 90 degrees(e.g. 270 degrees).

Detail E in FIG. 4B shows a cladding assembly 600 for securing fourpanels in the middle, which form more or less a flat or relatively flatsurface. Similar to detail D, each cladding panel has an anchor block100 mounted within a mounting channel 320 and removably fastened to acorresponding hanging clip 200. A single piece T bracket 420 may be usedto interlock all four hanging clips 200, and another single piece Lbracket 410 may be removably fastened onto T bracket 420. L bracket 410may have two slots or bores for receiving corresponding fasteners 430 a,430 b when mounted to a building structure (not shown).

FIG. 4C shows perspective views of further different configurations ofexample cladding assemblies for bottom panels 300 a, 300 b. Referringnow to detail G, which shows two cladding assemblies 600 a, 600 b eachmounted on respective bottom cladding panel 300 a, 300 b, as these twopanels 300 a, 300 b are assembled to form a corner of less than or equalto 90 degrees. Hidden from view are anchor blocks 100 locked withinmounting channels 320. As can be seen, the cladding assembly 600 a onthe left has identical components and configuration as cladding assembly600 b on the right. Referring now to cladding assembly 600 b installedon the right cladding panel 300 b in detail G, only one anchor block 100and one corresponding hanging clip 200 are required. Two bores 220 maybe drilled in the hanging clip 200 for receiving fasteners 260 in orderto removably fasten the hanging clip 200 to the corresponding anchorblock 100 thus the panel 300 b. In addition, support 400 may comprisetwo L brackets 410 a, 410 b. One of the L brackets 410 b may have two ormore bores for receiving corresponding fasteners 430 a, 430 b whenmounted to a building structure (not shown).

Detail J in FIG. 4A shows identical assemblies 600 a, 600 b as those indetail G, except that in detail J, these two cladding panels 300 a, 300b are assembled to form a corner greater than 90 degrees (e.g. 270degrees).

Detail H in FIG. 4A shows a cladding assembly 600 for securing twobottom panels in the middle, which form more or less a flat orrelatively flat surface. Similar to detail G, each cladding panel has ananchor block 100 mounted within a mounting channel 320 and removablyfastened to a corresponding hanging clip 200 a, 200 b. A single piece Lbracket 410 a may be used to interlock both hanging clips 200 a, 200 b,and another single piece L bracket 410 b may be removably fastened ontobracket 410 a. L bracket 410 b may have two or more slots or bores forreceiving corresponding fasteners 430 a, 430 b when mounted to abuilding structure (not shown).

Embodiments described herein may provide a method for installing acladding panel onto a building structure, the cladding panel having amounting channel extended across at least a part of a surface of thecladding panel, the anchor block having at least one bore extendinginwardly from an outer surface thereof. The method may involve embeddingthe anchor block into the mounting channel of the cladding panel in aninterlocking fit, such that an outer surface of the anchor block isflush or near flush with the surface of the cladding panel when theanchor block is received within the mounting channel; removably securinga hanging clip to the embedded anchor block by inserting a fastenerthrough a corresponding bore extending through a body of the hangingclip and the at least one bore of the anchor block; and securing thecladding panel onto the building structure by connecting or fasteningthe hanging clip to a support. As shown in FIGS. 4A and 4B the methodmay involve different configurations of the hanging clip depending onthe type of support provided and the positions of the cladding panel tosupport. The method may be repeated to secure multiple cladding panelsin different configurations. In some embodiments, the method may involveadjusting a position of the support to provide at least a horizontaladjustment of the cladding panel relative to the support.

In some embodiments, the support is removably coupled to the buildingstructure and comprises at least one of an L bracket and a T bracket.Different bracket configurations and types may be used depending on thedesired configuration of the hanging clip. This provides flexibility indesign as embedded anchors and hanging clips may be used to supportvarious cladding panels in different positions relative to the buildingsupport.

The method may involve sliding the anchor block into the mountingchannel of the cladding panel and/or involve filling a gap between themounting channel and the embedded anchor block with adhesive material.The method may involve embedding the anchor block in position within themounting channel using elastic materials. The method may involveadjusting a position of the hanging clip through the at least onecorresponding bore to provide vertical adjustment of the cladding panelrelative to the support.

In some embodiments, the anchor block has a core and two engagingportions outwardly projecting from the core, the two engaging portionsoperable to lock the anchor block in the mounting channel of thecladding panel in the interlocking fit when the embedded anchor block isreceived within the mounting channel. In some embodiments, the mountingchannel has a cross section complementary to a cross section of a shapeof the embedded anchor block. In some embodiments, the hanging clipcomprises an engagement surface to engage the outer surface of theembedded anchor block. In some embodiments, the hanging clip isremovably connected or fastened with the anchor block by a threaded boltor an expansion bolt.

FIG. 5 is an exploded view of an example anchor block 100 and an examplehanging clip 200 system with a cladding panel 300. Cladding panel 300may comprise a mounting channel 320 extending at least partly across asurface 310 thereof. Anchor block 100 may have an outer surface 130 thatis configured to be flush or near flush with the surface 310 of thecladding panel 300 when the anchor block is received within the mountingchannel in an interlocking fit. A cross section 330 of mounting channel320 may have a complementary outline or shape as a corresponding crosssection 160 of anchor block 110.

In some embodiment, anchor block 100 has a dovetail shape as shown. Thedovetail shape may facilitate an interlocking fit between anchor block100 and mounting channel 320 when anchor block 100 is received withinmounting channel 320. As described herein, anchor block 100 may have anyother suitable shape.

A hanging clip 200 may be configured to be removably fastened to anchorblock 100, the hanging clip having an engagement surface 210 to engagethe outer surface 130 of anchor block 100, where the cladding panel 300is operable to be secured to a building structure 500 by fasteninganchor block 100 to the hanging clip 200 which is removably securable toa support 400.

In some embodiments, anchor block 100 may have at least one bore 140extending inward from outer surface 130 and hanging clip 200 has atleast one corresponding bore 220 to removably fasten hanging clip 200 toanchor block 100 with a fastener 260 through bores 220, 140. Fasteners260 may be threaded or expansion bolts. In addition, flat washers orlock washers may be used with fasteners 260 to removably connect hangingclip 200 and anchor block 100.

In some embodiments, adhesive material may be used to fill a gap betweenanchor block 100 and an inner surface of mounting channel 320 whenanchor block 100 is received within mounting channel 320.

In some embodiments, outer surface 130 of anchor block 100 may comprisegrooves 150 thereon for preventing slippage when removably fastened withhanging clip 200.

In some embodiments, in order to increase the impact resistance of thecladding panel, a reinforcing layer 340 can be added on the surface,such as carbon fiber and resin, glass fiber and resin, and so on. Thereinforcing layer can cover the surface 310 of cladding panel 300 in theform of cloth, mesh, grid or grating. A function of reinforcing layer340 is to prevent cladding from shattering when it is broken. Thisgreatly increases the safety factor in real application to lower therisk of injury by falling cladding materials.

In some embodiments, entire surface of the decorative panels, mesh, suchas strengthening the grid-like layer 340 may be enhanced to increase itsimpact resistance such that damage may be avoided or minimized.

FIG. 6 is a perspective view of an example hanging clip 200 inaccordance with some embodiments. Hanging clip 200 may comprise a body230 and a flange 240 projecting outwardly from the body 230, wherein thebody having the at least one slot or bore 220 corresponding to each ofat least one bore 140 of anchor block 100 for removably connecting orfastening the anchor block 100.

An engagement surface 210 of hanging clip 200 may comprise grooves 250thereon for preventing slippage when engagement surface 210 is incontact with outer surface 130 of anchor block 100.

Grooves 150, 250 on anchor block 100 or hanging clip 200 may helpincrease friction or act a pure mechanic lock if necessary.

FIG. 7 is a perspective view of an example anchor block 100. As can beseen, anchor block 100 may have an outer surface 130 that is configuredto be flush or near flush with the surface 310 of the cladding panel 300when the anchor block is received within the mounting channel in aninterlocking fit. One or more bores 140 may be drilled into anchor block100 for engaging with hanging clip 200.

Referring now to FIGS. 8A to 8C, cross-section views of variousembodiments of anchor block 100 are shown. As can be seen, anchor block100 may have a core 110 and two engaging portions 120 outwardlyprojecting from the core, the two engaging portions 120 operable to lockanchor block 110 in mounting channel 320 of cladding panel 300 in aninterlocking fit when anchor block 100 is received within mountingchannel 320.

In FIG. 8A, anchor block 100 may comprise a dovetail shape. Two engagingportions 120 a, 120 b may each have an angle 170 of A degrees, where Amay be greater than 0 and less than 90 degrees. In FIG. 8B, the twoengaging portions 120 a, 120 b may each be in the form of a rectangle ora square. In FIG. 8C, the two engaging portions 120 a, 120 b may each bein the form of a semi-circle or generally round shape.

In some embodiment, anchor block 100 may comprise material such asmetal, reinforced plastics, or any other suitable material. In oneembodiment, anchor block 100 as well as hanging clip 200 may comprisealuminum.

Anchor block 100 can be linear, arc (such as for cylindrical column) orother shapes as required. The number of threaded holes or bare holes 140on anchor block 100 can be one or more. The narrow surface of thedovetailed anchor is aligned with the back surface of cladding panel orcircular column, hanging clip is connected with the embedded anchor bymechanical fasteners.

Referring now to FIG. 9, which shows a side view of an example anchorblock 100 embedded within a cladding panel 300 and an example hangingclip 200 removably fastened to the anchor block. As can be seen,adhesive material 620 may be used to eliminate direct contact betweenanchor block 100 (e.g. metal) and cladding panel 300. The adhesivematerial 620 can also take or share shear load.

In accordance with one aspect of the invention, a method for installinga cladding panel onto a building structure is described herein. Duringoperation, a cladding panel may first be pre-fabricated with a mountingchannel extending at least partly across a surface thereof.Alternatively, cladding panel may be modified in a workshop to have themounting channel carved into a surface thereof. Next, anchor block maybe slid or otherwise placed into the mounting channel of the claddingpanel in an interlocking fit, such that an outer surface of the anchorblock is flush or near flush with the surface of the cladding panel whenthe anchor block is received within the mounting channel. Next, ahanging clip may be removably fastened to the anchor block by insertinga fastener through a bore extending through a body of the hanging clipand at least one corresponding bore of the anchor block. Finally, thecladding panel may be installed or hung onto the building structure byfastening the hanging clip to a support. The support may comprise atleast one of a T bracket and a L bracket.

In some embodiments, the anchor block may be squeezed in position withinthe mounting channel by using suitable engineering plastics, elastic oradhesive materials.

In some embodiments, a position of the hanging clip may be adjusted to acertain degree through the at least one corresponding bore of thehanging clip to provide vertical adjustment of the cladding panelrelative to the support.

In some embodiments, a position of a component in the support (e.g. Tbracket or L bracket) may be adjusted to provide at least a horizontaladjustment of the cladding panel relative to the support.

FIG. 10A demonstrates stress analysis by FEA on a cladding panel. FIG.10B demonstrates stress analysis by FEA on an anchor block and a hangingclip assembled.

FIG. 11 shows deflection analysis by FEA for a cladding supportingstructure under design load.

FIG. 12 shows an example installation sequence of the cladding assemblysystem. As shown, cladding panels may be supported on a building usingthe hanging assembly described herein. The cladding panels may beattached using various sequences and configurations given the flexibleand adaptable hanging assembly which may facilitate the constructionprocess.

In some embodiments, the cladding systems and methods described hereinmay provide ease of use during manufacturing process and siteconstruction procedure. For example, it may benefit from maximum in-shopfabrication. On a construction site, only several operations arerequired to complete the installation work, such as position adjustment,mechanical fastening, simple adhesive bonding and so on. Operations onsite do not tend to require highly skilled worker, such as experiencedmasonries, and general labors can complete the installation work. Underthis condition, site installation efficiency may be increased,installation time may be greatly shortened, unit labor rate can bethereby reduced.

In some embodiments, the systems and methods for cladding describedherein may shift a large amount of man-hours generally required onconstruction site into workshop. This further reduces a high cost atsite construction site and replaces such high cost with a lower cost atworkshops, which at the same time, also increases accuracy ofmanufacturing.

In some embodiments, the systems and methods for cladding describedherein may also minimize adverse effects from weather and climateconditions, and consequently minimizes some risks in delay of projectdelivery.

In some embodiments, the systems and methods for cladding describedherein may also reduce waste generation on site and provide a green andenvironmental-friendly construction environment. Waste generated by theprocess is generally easy to handle, environmentally friendly, and maybe dealt with easily at a waste processing plant.

In some embodiments, the systems and methods for cladding may relate tonatural stone, artificial stone ceramic tiles, and other buildingmaterials as decorative panels. The back of the decorative panel mayhave an extending channel or groove that may open wide at an edge toreceive the embedded anchors with threaded holes (or hole) to removablyconnect to the hanging clips via corresponding pendant with bolt (orbolts). The connection may be provided with screws to fix the bodymember (e.g. cladding) to the hanging assembly (anchor, hanging clip). Atrim panel may be used in some embodiments for practicability and value.

In some embodiments, the systems and methods for cladding or newdecorative panels may be produced entirely within the factory forbenefits such as high precision, less-site adjustment, uniform forcetransfer, and reasonable stress distribution.

In some embodiments, with neatly machined surface of the claddingpanels, transportation may be convenient. For example, the embeddedanchor supports may be flush or near flush with the surface of thecladding panels so that the cladding panels may be stacked withoutexcess wasted space that may results from components protruding orextending out of the cladding panels. A stack of cladding panels withthe embedded anchor supports therein may be substantially the sameheight as the same stack of cladding panels (i.e. the same number ofcladding panels in the stack) without the embedded anchor supports. Theembedded anchor supports may be made of relatively light weight materialto reduce excess weight for shipping.

These are illustrative example embodiments and there may be othervariations and modifications.

What is claimed is:
 1. A cladding panel assembly comprising: a claddingpanel; a mounting channel extending laterally across said claddingpanel; and an anchor block received in the mounting channel of thecladding panel, said anchor block and said mounting channel havingcross-sectional shapes defining an interlocking fit so that said anchorblock is slidable laterally within the mounting channel.
 2. The assemblyof claim 1, wherein the embedded anchor block has a dovetail shape. 3.The assembly of claim 1, wherein the mounting channel has a crosssection complementary to a cross section of a shape of the embeddedanchor block.
 4. The assembly of claim 1, further comprising a hangingclip removably mounted to the embedded anchor block with a firstadjustable fastener permitting vertical adjustment of the hanging cliprelative to the anchor block.
 5. The assembly of claim 4, wherein thefirst adjustable fastener comprises a threaded shaft received in a boreextending inward from the outer surface, and received through a slot inthe hanging clip.
 6. The assembly of claim 5, comprising a flangeprojecting outwardly from the cladding panel for receiving a secondadjustable fastener to adjustably fix the cladding panel to a building.7. The assembly of claim 6, wherein the flange is part of a bracketreceived in a slot defined by the hanging clip.
 8. The assembly of claim7, wherein the second adjustable fastener comprises a shaft receivedthrough a slot in the flange.
 9. The assembly of claim 3, wherein theouter surface of the embedded anchor block comprises grooves thereon forpreventing slippage when removably connected or fastened with theengagement surface of the hanging clip.
 10. The assembly of claim 8,wherein the engagement surface of the hanging clip comprises groovesthereon for preventing slippage when removably connected or fastenedwith the embedded anchor block.
 11. The assembly of claim 1, wherein thecladding panel further comprises a reinforcing layer on the surface in aform of at least one of cloth, mesh and grating.
 12. A kit for hanging acladding panel onto a building structure, the cladding panel comprisinga mounting channel extending laterally across a surface thereof, the kitcomprising: an anchor block having a cross-sectional shape forinterlocking reception in the mounting channel of the cladding panelsuch that the anchor block is laterally Is; and a hanging clipconfigured for mounting to the anchor block using a first adjustablefastener received through a slot such that the vertical position of thehanging clip relative to the anchor block is adjustable.
 13. The kit ofclaim 12, wherein the first adjustable fastener comprises a threadedshaft received in a bore extending inward from the outer surface. 14.The kit of claim 13, comprising a bracket mountable to the hanging clipto receive a second adjustable fastener to fix the cladding panel to thebuilding structure.
 15. The kit of claim 14, wherein the bracket isconfigured for reception in a slot defined by the hanging clip.
 16. Thekit of claim 15, wherein the bracket comprises a flange with a slottherein for receiving said second adjustable fastener.
 17. The kit ofclaim 11, wherein the outer surface of the anchor block comprisesgrooves thereon for preventing slippage when removably connected orfastened with an engagement surface of the hanging clip.
 18. The kit ofclaim 17, wherein the engagement surface of the hanging clip comprisesgrooves thereon for preventing slippage when removably connected orfastened with the anchor block.
 19. A method for installing a claddingpanel onto a building structure, the cladding panel having a mountingchannel extended across at least a part of a surface of the claddingpanel, the anchor block having at least one bore extending inwardly froman outer surface thereof, the method comprising: inserting the anchorblock into the mounting channel of the cladding panel in an interlockingfit and adjusting the position of the anchor block by sliding the anchorblock within the mounting channel; removably securing a hanging clip tothe embedded anchor block by inserting a fastener through acorresponding bore extending through a body of the hanging clip and theat least one bore of the anchor block; adjusting the vertical positionof the hanging clip relative to the anchor block using the fastener; andsecuring the cladding panel onto the building structure by connecting orfastening the hanging clip to a support
 20. The method of claim 19,wherein securing the cladding panel comprises fastening a bracket to thesupport, the bracket extending away from the cladding panel, and furthercomprising adjusting the position of the bracket relative to thecladding panel.